A device for cooling a vehicle battery is provided that includes a plurality of electrical storage elements, and a cooling element having ducts for a fluid to flow through, wherein the electrical storage elements are in thermal contact with the cooling elements and heat can be transmitted from the storage elements to the fluid, and wherein the cooling element which comprises the ducts is embodied as at least one extruded profile.
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14. A device for cooling a vehicle battery, the device comprising:
a plurality of electrical storage element; and
a cooling element having channels embedded therein for passage of a fluid,
wherein the electrical storage elements are in thermal contact with the cooling element such that heat is transmittable to the fluid from the storage elements,
wherein the cooling element, including the passages, is configured as one extruded profile,
wherein the channels are spaced apart along a width direction of the cooling element, and
wherein a central region of the cooling element, in the width direction, has a smaller thickness than other regions of the cooling element.
1. A device for cooling a vehicle battery, the device comprising:
a plurality of electrical storage devices; and
a cooling element having channels for passage of a fluid,
wherein the electrical storage devices are in thermal contact with the cooling element such that heat is transmittable to the fluid from the storage elements,
wherein the cooling element including the passages is configured as one extruded profile,
wherein the cooling element includes a first flow in a first plane and at least one second flow in a second plane, wherein the first plane is substantially parallel to the second plane, and
wherein the cooling element has walls for accommodating the electrical storage elements between the walls, the walls extending perpendicular to the first and second planes.
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This nonprovisional application is a continuation of International Application No. PCT/EP2009/003916, which was filed on Jun. 2, 2009, and which claims priority to German Patent Application No. DE 10 2008 027 293.0, which was filed in Germany on Jun. 6, 2008, and which are both herein incorporated by reference.
1. Field of the Invention
The invention concerns a device for cooling a vehicle battery.
2. Description of the Background Art
The cooling of electrical energy storage devices of modern motor vehicles poses special demands on account of the sometimes high power density. Such energy storage devices can be used as batteries for electric or hybrid vehicles, among other uses. These can be lithium-ion batteries, supercaps, fuel cells, conventional rechargeable batteries, or combinations of such elements. A number of proposals for efficient cooling of such components are known, although these are often laborious or costly to produce. For example, cooling plates for electric elements have been proposed that are assembled from two halves, with passages for conducting a coolant being introduced into one of the halves by milling.
It is an object of the invention is to provide a device for cooling a motor vehicle battery that can be manufactured easily and economically, and that provides effective and reliable cooling. As a result of the fact that the cooling element including the passages is designed as at least one extruded profile, production costs can be kept low since the number of joints, and thus of manufacturing steps and possible sources of leakage, is reduced. At the same time, an extruded profile with passages provided therein offers high pressure resistance, which can be advantageous in particular when the cooling element is used as the evaporator of a refrigeration circuit.
In an embodiment, the fluid is a coolant of a cooling circuit. Alternatively or in addition, the coolant can also be a refrigerant of a refrigeration circuit, wherein the cooling element is designed as the evaporator for the refrigerant. A coolant is hereinafter understood to be a heat-transmitting fluid, in particular but not necessarily in the liquid phase, which undergoes virtually no phase change when flowing through the cooling element. In the case of a refrigerant in the sense used by the detail designs according to the invention, an evaporation of the refrigerant generally takes place in the cooling element, wherein the cooling element is a component of a refrigeration circuit with a compressor, gas cooler/condenser, and expansion element. In this context, the refrigeration circuit can include an air conditioning system of the vehicle, in particular.
In an embodiment, the cooling element can be multiple flow, in particular dual flow, in design, wherein a first fluid flows through some of the passages and a second fluid flows through other passages. This makes it possible, for example, to connect both to a cooling circuit with a first fluid as circulating coolant, as well as to a refrigeration circuit with the second fluid as circulating refrigerant. In this way, it is possible to ensure cooling in different operating situations, in particular when the vehicle air conditioner is switched off or faulty.
The extruded profile can have at least one region in its cross-section that is not traversed by passages, in particular for fastening the electrical elements. In especially advantageous manner, the region of the cooling element that is not traversed by passages can have a smaller outer diameter than the region that is traversed by passages in this design. The thinner region thus contributes to saving weight and material, and at the same time can be used for fastening the electrical elements or retaining members for the elements, for instance by means of holes or internal threads. In particular, such an embodiment can be designed in a simple manner such that the cooling element has a few, in particular just one, extruded profile.
A header can be arranged on the cooling element for distributing the fluid over the multiple passages, wherein the header is provided at the end of the extruded profile and at least some of the passages terminate in the header.
In an embodiment, the header can have a baffle extending in its longitudinal direction, in particular wherein chambers of the header separated by the baffle are associated with different passages of the cooling element. A header with a baffle of this nature can thus allow the distribution of different fluids over different groups of passages.
Alternatively or in addition, the header can have a baffle extending in its transverse direction. Such a header allows, in a simple way, arrangements in which one or more reversals of the fluid's direction take place at the ends of the extruded profile, for example in the case where the flow through the cooling element is in a serpentine pattern.
To ensure especially even distribution of the fluid over the multiple passages, the header can have a variable cross-section in the fluid's flow direction. In this context, the variable cross-section can be designed in a simple way by a variable penetration depth of the cooling element in the header.
In an embodiment, the header can have a first chamber and a second chamber, wherein the chambers are arranged one behind the other in the longitudinal direction of the flow passages, and the ends of a first group of flow passages for connection to the first chamber extend past a second group of flow passages that are connected to the second chamber. Such a construction permits, in particular, nearly any desired association of the different passages with two separate flows of the cooling element.
Alternatively or in addition to the provision of a header, a manifold block for supplying one or more fluids can be located on the cooling element, wherein the manifold block is connected to the passages through openings provided perpendicular to at least some of the passages. For a manifold block as well, provision can be made in a possible embodiment for the manifold block to include at least two flows.
In an embodiment, the cooling element can comprise multiple extruded profiles, wherein at least one, in particular a plurality, of the passages is formed in each of the extruded profiles. In this way, cooling elements of varying width can be implemented by using identical parts, among other techniques.
In another embodiment of the invention, the path of the cooling element can be curved or bent. This is accommodated especially well by the use of extruded profiles with passages integrally formed therein of the same material, since there are no joints in the vicinity of the bends that could be damaged. It is especially preferred here for the cooling element to have at least one, in particular multiple, bends about approximately 180°, wherein the electrical storage elements are arranged between parallel, flat sections of the cooling element. Among other things, this allows two opposing sides of a storage element, for example of a flat battery such as those in the “coffee bag” design, to be cooled over their full areas by the two parallel, flat sections. Alternatively or in addition, by means of its bending the cooling element can also be matched to a cylindrical surface shape of a storage element, in particular, in order to optimize the size of the thermal contact area.
In another embodiment, the cooling element can have a prismatic element with walls for accommodating the electrical storage elements. It is especially preferred in this design for the prismatic element to be enclosed by the extruded profile as a single piece and in the same material, which is to say to simultaneously be a constituent part of the extruded profile. Depending on requirements, however, it can also be a separate component, for example a component soldered over its area to the cooling element, which can likewise be an extruded profile, particularly in the interests of simple manufacture.
In an embodiment, the electrical elements do not have an inherently rigid envelope, wherein the elements are designed in particular as flat bodies or “coffee-bag” cells. Such designs are used for lithium-ion batteries in particular, which are especially interesting for modern traction batteries because of their power density.
Alternatively or in addition, the electrical elements can have an inherently rigid envelope, wherein the elements are designed as cylindrical bodies in particular. Such cylindrical designs are widespread as well and are also encountered in lithium-ion batteries.
In the interests of easy assembly combined with good thermal contact, the electrical elements can be secured to the cooling element by means of a clamping frame. It is advantageous in this design for the clamping frame to hold one or more of the electrical elements by elastic clamping. In this way the elements can be inserted in a latching manner during assembly or maintenance, wherein a resultant spring force in the direction of a thermal contact surface is also present in the assembled state when the clamping frame is designed suitably.
In an embodiment, the clamping frame is divided into two pieces, wherein an electrical element, which in particular is not inherently rigid, is held between two parts of the clamping frame. By means of two-piece or three-piece clamping frames, “coffee-bag” cells, for example, can be mounted easily and reliably, with a particularly large surface of the cells at the same time being in reliable contact with the thermally conducting, in particular metallic, clamping frame.
In an embodiment, provision is made for two electrical elements, which in particular are not inherently rigid, to be supported by means of a spring element located between them, by which means a thermal contact is improved and expansions due to temperature or charge state of the electrical storage devices are compensated. Such a spring element is understood to include a layer of elastic nonwoven mat or the like in addition to metallic springs made of corrugated sheet metal, for example.
In an embodiment, a plurality of the electrical elements can be joined into a preassembled stack to improve the manufacturing flows and in the interest of controlling costs and quality, wherein the preassembled stack is placed on the cooling element.
In an embodiment, the electrical elements can be secured over their area to a cooling plate that can be attached to the cooling element. It is especially preferred in this regard for the electrical elements to be additionally attached to one or more plastic parts, wherein the cooling plate, the plastic parts, and the electrical elements together form a preassembled stack for attachment to the cooling element.
Depending on the requirements, however, the elements can also be secured directly to the cooling element, for example by gluing.
In another embodiment, the cooling element can have a first flow and at least one second flow that is located in a plane parallel to the first flow. It is preferred in this regard for the first and second flows to be connected together by a diverter block, so that the inlet and outlet can be located on the same side of the cooling element.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:
In each case, the electric elements cooled in the exemplary embodiments described below are lithium-ion batteries, while other elements, such as NiMH batteries or supercaps, may also be provided depending on requirements.
In the first exemplary embodiment shown in
In the variation from
In particular, multiple battery cells can be positioned next to one another on the cooling elements, not only in the longitudinal direction, but also in the transverse direction.
In the variation from
As shown in
In addition to a single-flow design, the cooling element can also be implemented as a dual flow design as in
In general, the headers can have any desired cross-sectional shape, such as round, oval, rectangular or trapezoidal. Grooves into which the headers are inserted are provided on the end faces or in the end regions of the surface for installation on the cooling element. By means of solder-plating of at least some of the parts, the assembled arrangement can be soldered in a soldering oven, which naturally takes place before an installation of the electrical elements.
Of course, the header 6 can also be designed as a single-piece machined part, in particular a milled part.
In the present case, the electrical elements are flat lithium-ion cells in the “coffee bag” design, which do not have an inherently rigid envelope. In order to compensate for thermal and charge-related expansion, nonwoven mats 20 are arranged on one side of each of the elements.
In
The stack can be placed on the cooling element as a unit and can be attached thereto by screws and/or gluing, for example. This considerably simplifies mass production of an inventive device. At the same time, the leads are held in a defined position, particularly in the case of cells 18 that are not inherently rigid.
It is a matter of course that the individual features of the exemplary embodiments described above can be appropriately combined with one another according to requirements.
In this exemplary embodiment, the cooling element 1 is likewise designed as an extruded profile and has a first flow 30 and a second flow 30′ that is arranged substantially parallel to the first flow. As indicated by arrows, the first fluid flows into a manifold block 11 and through the first flow 30. It is then returned to the manifold block 11 via a diverter block 32 and a second flow 30′, which is located below the first flow.
In this design, the first flow 30 is responsible for cooling the storage elements 18. The second flow 30′ serves solely to return the coolant, so that inlet and outlet can be located on the same side of the cooling element 30. The second flow 30′ has essentially no effect on the cooling of the storage elements, and is thus designed so that the pressure drop is kept as small as possible.
Located between the first flow 30 and the second flow 30′ is a blind passage 31, which has no connection to the manifold block 11 or the diverter block 32. This blind passage serves the purpose of thermal isolation of the two flows 30 and 30′, and it is filled with air, for example, or another insulating material.
The blind passage 31 is optional, because in some cases this thermal separation is undesirable in the interests of equalizing the temperature of the cooling element. In this exemplary embodiment, the second flow 30′ then likewise takes on a heat-transmitting function.
The important advantages of this embodiment from.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.
Pfender, Conrad, Schiehlen, Thomas, Heckenberger, Thomas, Steinbach, Martin, Schmid, Caroline, Kohlberger, Markus, Wiebelt, Achim, Herrmann, Hans-Georg, Moldovan, Florian, Isermeyer, Tobias, Eckstein, Juergen, Fehren-Bacher, Christoph
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